Installing DrDiff rear disc brakes on a Dana 60

[shawge]

Documenting the install of Dr Diff rear disc brakes on a Dana 60.

Early last year I purchased a 11.7" rear disc brake kit from Cass (Dr Diff).  The kit includes Cobra calipers and rotors, and all the hardware to install discs on the rear of an 8.75 or Dana 60.

Later on, I acquired a B-body width Strange Dana 60 from Cass with oversize bearings.  The bearings are Set20/A20 and are also called "big Ford" or "Torino" bearings.   Using these bearings requires the caliper bracket in the Dr Diff kit to be modified.  The large hole in the caliper bracket needed to be enlarged to 3.160" to clear the 3.150" bearings (brads70 has a pic showing how he enlarged the bracket with a mill).  No modification is required if OEM or "green" bearings are used.

Pictures are showing the install on the Left side.

Remove wheel




Remove bearing retainer




Another view of the U-shaped retainer and bearing




Slip caliper bracket onto axle, flat face of caliper bracket goes towards the outside and the bracket is angled towards the rear of the car.  Note that gaskets are NOT required when using the Set20 bearings - using OEM bearings will require the use of foam and/or steel gaskets.  The U-shaped bearing retainer will seat the bearing and compress enough to secure the caliper bracket. 

Now is a good time to install the brake line  bracket.  Much easier to do before things start getting in the way.  There are two sets of small threaded holes.  The bracket is fastened to the upper set of holes, on the side facing towards the differential.  I have a picture showing the bracket and flexible line orientation later on in this thread.




Make sure the bearing race is clean and reinstall the axle shaft  Reinstall the U-shaped bearing retainer and torque the nuts to 35 ft-lbs.




Test fit the rotor and caliper.  The caliper will need to be centered on the rotor with the shims provided in the brake kit.  I had to use two shims on both caliper bolts to get it centered.  Once centered, tighten down the caliper bolts





Attach the flexible brake hose to the caliper with two copper crush washers and a banjo bolt, routing the hose down from the caliper and then up to the brake line bracket.   Tighten down the banjo bolt.




Reinstall the wheel and torque the lug nuts as per FSM




It took me about 45 minutes per side to install the discs to the point of where I can now attach the axle hard brake lines and parking brake cables

TODO - I will add pictures for these at a later date:
- bend and install new axle brake lines
- install the parking brake cables

[70chall440]

Love the wheels.

[Chryco Psycho]

 
 My diff was built the same way with the ford tapered brg  but I have not installed rear disc so far I am still using 10" drums

[Katfish]

Following along, may be in my future.
Does it retain the parking brake?

[shawge]

Katfish, there is parking brake.  I am not sure the original parking brake cables would work.  Since I needed new ones, I bought the cables offered by DrDiff.  In the second to last picture there is a large spring attached to a lever on the caliper.   The cable would attach to that lever and then be routed to the original parking brake connection.  I'll snap some pictures when I get that installed.

[brads70]

Nice rims! 

Here are a few pictures if it helps someone down the road. I used the smaller brake kit from Cass and his supplied parking brake cables.  Rear calipers and pads are '94-'04 Mustang Cobra (not GT). Rotors are from a 1989 Toyota Cressida  rear brakes. I supplied my own ( not from Cass) so they would match my front rotors , so I had to bore them out to fit the Dana hub center.